Press molded door with improved reinforcement material and stile structure

ABSTRACT

A press-molded door with an improvement for its interior reinforced material and stile structure comprises an interior reinforced material, handle&#39;s reinforced material, two top and bottom stiles, and two left and right stiles. The two left and right stiles are inserted with each other by its flexible-rigid co-extrusion convex structure and the concave structure of interior reinforced material, and are then connected with two top and bottom stiles forming a closed space and an imitation wood grain door.

BACKGROUND

[0001] This invention relates to a stile structure and interior reinforcement of the press molded door, especially to a press molded door with an improvement on its material and stile structure.

PRIOR ART

[0002] It is known in these category that there is a Taiwan Utility Model application no. 84204994, titled as “An improvement for the assembly structure of pressed-molded door”, applied and granted prior to this invention. However, the said patent has defects regarding the gluing process, material used, assembly time, and size flexibility. This invention is to solve the above problems and upgrade the efficiency for assembly.

SUMMARY OF THE INVENTION

[0003] This invention relates to the press molded door with an improvement for reinforced material and stile structure comprising two door panels, two top and bottom stiles, two left and right stiles and an interior reinforced material, is characterized by that the flexible-rigid co-extrusion convex structure of the interior reinforced material. The above mentioned interior reinforced material is made with the door panel together by a single mold that can reduce the assembly time, enhance the strength of door and the stability of quality. The above mentioned reinforced material used in the handle is set inside the interior reinforced material to form a closed space with two top and bottom stiles. Finally an imitation wood grain door is finished.

[0004] Besides, the above mentioned left and right reinforced material of this press molded door has a groove to be connected with the convex part of the left and right stiles, and then combine with top and bottom stiles and two door panels to form a closed space. After that, it is drilled a hole on the bottom stile for filling of polyurethane inside to make an imitation wood grain door.

[0005] Moreover, the press-molded door of this invention can be made different width according to customers' needs, by cutting two sides of the door.

[0006] Furthermore, by putting the left and right stiles with different width, we can get a door with different width.

BRIEF DESCRIPTION OF DRAWING

[0007] The following are illustrative drawing examples of the invention:

[0008]FIG. 1 is a section view of plastic-extruded interior reinforced material, wherein the material used is PVC (polyvinyl chloride) having two concave areas (16) of 2.2 mm width and 4.5 mm depth on each of two sides to be inserted with the ribs (121,122′ in FIGS. 5,6) on two sides of door panel (FIGS. 7, 8, 9). In the middle part of two sides having groove shape (13) to be tightly joined with the flexible-rigid co-extrusion convex part (12, 12′ in FIGS. 3, 4) of the left and right stiles. In addition, there is a hollow convex structure (18) at respective distance of interior reinforced material to support the door panel (71,81,91 in FIGS. 7,8,9) and to provide construction strength.

[0009]FIG. 2 is the perspective view of plastic-extruded interior reinforced material, wherein said reinforced material having a hole of 80 mm width and 400 mm length punched on its side to be set the handle's reinforced material (10 in FIGS. 7,8,9), and where the hollow convex part can be matched with various types of door panels (71,81,91 in FIGS. 7,8,9).

[0010]FIG. 3 is the perspective view (type 1) of the left and right stiles, wherein the middle part of said stile's “T” shape appearance is flexible-rigid co-extrusion material (12) having convex (121) on both sides to be tightly glued with door panel (71, 81, 91 in FIGS. 7, 8, 9) and interior reinforced material (10 in FIGS. 7, 8, 9) to form a stile structure of 6 mm width.

[0011]FIG. 4 is the perspective view of left and right stiles (type 2), wherein the middle part of said stile's “T” shape appearance is flexible-rigid co-extrusion material (12) having convex (121′) at both sides to be tightly glued with the door panel (71,81,91 in FIGS. 7,8,9) and the interior material (10 in FIGS. 7, 8, 9 ), and then formed a stile structure of 10 mm width.

[0012]FIG. 5 is the construction view (type 1) before and after the assembly of left and right stiles, and its related location with the door panel (71, 81,91) having ribs (17) and the interior reinforced material. Numerals 5, 5′ expresses the details of the left and right stiles of “T” type appearance; whereas numerals 13 illustrates that the concave part of the interior reinforced material is designed to be tightly glued with the flexible-rigid co-extrusion convex part of the left and right stiles. The drawing on right side specifies the related positions among the door panels (71,81,91), the interior reinforced material (7) and the construction view (type 1) before and after the left and right stiles' assembly.

[0013]FIG. 6 is the related positions among the door panel (71,81,91) having ribs (17), the interior reinforced material (7) and the construction view (type 2) of the left and right stiles before and after assembling. Numerals 5, 5′ expresses the details of the left and right stiles of “T” type appearance; whereas numerals 13 illustrates that the concave part of the interior reinforced material is designed to be tightly glued with the flexible-rigid co-extrusion convex part of the left and right stiles. The drawing on right side specifies the related positions among the door panels (71,81,91) and the interior reinforced material (7) and the construction view (type 2) before and after the left and right stile's assembly.

[0014]FIG. 7 is the related position of this door assembly drawing (type A) matching with door panel of this type. The assembling steps are as following:

[0015] (1). To face up the interior of door panel (71) having ribs (17 in FIGS. 5,6);

[0016] (2). To glue on every connected areas;

[0017] (3). To put the interior reinforced material (7), handle's reinforced material of rectangular solid (10) and the top and bottom stiles (8, 9), on the door panel;

[0018] (4). To glue on the required areas of another door panel;

[0019] (5). To put the left and right stiles inside two door panels (5,5′);

[0020] (6). To wait for the drying of glue and finish the assembling steps.

[0021] The top and bottom stiles (8, 9) could be wood, plastic injection piece or extrusion piece.

[0022]FIG. 8 is the related position for this door assembly drawing (type B) while matching with another door panel. The assembly steps are as following:

[0023] (1). To face up the interior of door panel (81) having ribs (17 in FIGS. 5, 6) on two sides;

[0024] (2). To glue on every connected areas;

[0025] (3). To put the interior reinforced material (7), handlers reinforced material of rectangular solid (10) and the top and bottom stiles (8, 9), on the door panel;

[0026] (4). To glue on the required areas of another door panel;

[0027] (5). To put the left and right stiles inside two door panels (5, 5′);

[0028] (6). To wait for the drying of glue and finish the assembling process.

[0029] The top and bottom stiles (8, 9) could be wood, plastic injection piece or extrusion piece. FIG. 9 is the related position for this door assembly drawing (type C) while matching with another door panel. The assembly steps are as following:

[0030] (1). To face up the interior of door panel (81) having ribs (17 in FIGS. 5, 6) on two sides;

[0031] (2). To glue on every connected areas;

[0032] (3). To put the interior reinforced material (7), handle's reinforced material of rectangular solid (10) and the top and bottom stiles (8, 9), on the door panel;

[0033] (4). To glue on the required areas of another door panel;

[0034] (5). To put the left and right stiles inside two door panels (5, 5);

[0035] (6). To wait for the drying of glue and finish the assembling process.

[0036] The top and bottom stiles (8, 9) could be wood, plastic injection piece or extrusion piece.

[0037]FIG. 10 is the three dimensional explosive drawing of this door construction, which is separated to many elements to further realize the constitution of this invention. Numeral 7 is the plastic-extruded interior reinforced material acted as the primary body structure of the door, whose top and bottom are covered with door panels (71,81,91) having ribs on two sides. Numerals 5, 5′ are “T” shape's left and right stiles. Numerals 8,9 are top and bottom stiles setting on the sides of top and bottom, to constitute a closed space with left and right stiles.

[0038]FIG. 11 is the construction assembly drawing of filling polyurethane into this door. The steps are as following:

[0039] (1). To face up the interior of door panel (71,81,91) having ribs at two sides;

[0040] (2). To glue on every connected areas;

[0041] (3). To put the left and right reinforced material (14) having groove shape at sides, handle's reinforced material of rectangular solid (10) and the top and bottom stiles (8, 9), on the door panel;

[0042] (4). To glue on the required areas of another door panel;

[0043] (5). To put the left and right stiles inside two door panels (5, 5′);

[0044] (6). To wait for the drying of glue and finish the assembling process.

[0045] (7). To drill a hole at the bottom stile and fill the polyurethane into the door.

[0046]FIG. 12 is the three dimensional explosive drawing of the construction while filling into this door with polyurethane. This assembly door is separated to many elements for the further realization of this invention. Numeral 15, the polyurethane, and numeral 14, the left and right reinforced material having groove shape on its side, they constitute the primary body structure of the door. Numeral 10 is the handle's reinforced material of rectangular solid covered with door panels (71, 81, and 91). Numerals 5, 5′, “T” shape's left and right stiles, and numerals 8, 9, top and bottom stiles, form a closed space.

[0047]FIG. 13 is the drawing of related positions among the construction of polyurethane filling, the left and right reinforced material (14) of 3.6 mm width and 12 mm depth, the door panels (71,81,91) having ribs on both sides, and the left and right stiles having flexible-rigid co-extruded convex parts (12), before and after their tightly being connected with one another. Numeral 15 is polyurethane.

[0048] The construction of this invention comprises:

[0049] (1). two door panels (71,81,91) having ribs on both sides;

[0050] (2). a plastic-extruded interior reinforced material (7);

[0051] (3). two plastic-extruded left and right stiles (5, 5′) which can be 6 mm or 10 mm width as required;

[0052] (4). two top and bottom stiles (8, 9) and

[0053] (5). handle's reinforced material (10).

[0054] The door is centered with the plastic-extruded interior material (7), supporting with door panels (71,81,91) having ribs on both sides, and are glued and fixed together with each other. Due to the reinforced material is rigid PVC, there are convex hollow structures appropriated spaced in support of door panels. This single molded structure can reinforce the door strength, facilitate the assembling processes, reduce the defect products, and improve the defects of that the reinforced materials are scattered away and are assembled individually and thus causing waste of time and cost, and lack of strength.

[0055] The left and right stiles are made of PVC with co-extrusion technique, on which the co-extruded convex parts (12, 12′) are inserted with the concave parts of interior reinforced material and formulate a firm construction without gluing. Further, the rigid PVC is easy for modification, and is therefore can match special requirements of door or frame by modifying the appearance dimensions to prevent the defects of glue's overflow in conventional structure and the difficulty for partial modifying work.

[0056] Another model of this invention is that the left and right reinforced materials (14) having groove shapes are joined together with the convex parts of the left and right stiles (5, 5′), and then are matched with the top and bottom stiles and two door panels to form a closed space. After that, it is drilled a hole at the bottom stile for filling polyurethane to the inner part, and form an imitation wood texture door.

[0057] This invention can be made different dimensions of door width as required. The manufacturing method is that using a plastic-extruded interior reinforced material (7), the top and bottom stiles and two door panels to form a closed space. And by cutting the required width after gluing them together, cutting groove on both sides to make left and right stiles with groove shape. Then putting it to be inserted with the flexible-rigid coextruded PVC, to form an imitation wood grain door.

[0058] For the preceding method, its plastic-extruded interior reinforced material can be replaced by filling polyurethane to increase the flexibility and multi-patterns.

[0059] Generally, the raw material of door can be either thermosets or thermoplastics. During the manufacturing process of thermosets, the FRP (fiber reinforced plastic) additive is not compulsory, and the door made of can be recycled for other purpose to fulfill the requirement of environment protection. Besides, if adding Al (OH)₃ in the compounding, it can be fireproof providing living safety. If this invented door can replace wood-made door, it can reduce wood chopping in large amount, and protect the precious resource of forests.

[0060] In summary, this creation can save many manufacturing steps, simplify the assembling procedures, and cut down the manpower cost. Besides, this door structure is firm and easy for cutting, and it can anti-moisture and prevent door bending. Therefore, this invented door is useful, economic and creative, and can promote product quality, and as a result, is novel and nonobviousness.

BRIEF DESCRIPTION OF DRAWING

[0061]FIG. 1: the horizontal section view of interior reinforced material;

[0062]FIG. 2: the perspective drawing of interior reinforced material;

[0063]FIG. 3: the perspective drawing of left and right stiles (type 1);

[0064]FIG. 4: the perspective drawing of left and right stiles (type 2),

[0065]FIG. 5: the related positions of left and right stiles (type 1), door panel and interior reinforced material before assembling;

[0066]FIG. 6: the related positions of left and right stiles (type 2), door panel and interior reinforced material after assembling;

[0067]FIG. 7: the related positions for this door assembly drawing (type A) matching with door panel numerals 71 assembly;

[0068]FIG. 8: the related positions for this door assembly drawing (type B) matching with door panel numerals 81 assembly;

[0069]FIG. 9: the related positions for this door assembly drawing (type A) matching with door panel numerals 91 assembly;

[0070]FIG. 10: the three dimensional explosive drawing;

[0071]FIG. 11: the door assembly drawing of filling polyurethane;

[0072]FIG. 12: the three dimensional explosive drawing of filling polyurethane;

[0073]FIG. 13: the related positions for the structure of filling polyurethane, left and right stiles, door panel and left and right reinforced material.

MEANING OF NUMERALS USED IN THE DRAWING

[0074]1: the plastic-extruded interior reinforced material;

[0075]12: the convex part of flexible-rigid co-extrusion of left and right stiles (typel)

[0076]12′: the convex part of flexible-rigid co-extrusion of left and right stiles (type 1);

[0077]121: the convex part on top and bottom sides of left and right stiles (type 2);

[0078]121′: the convex part on top and bottom sides of left and right stiles (type 2);

[0079]5: the left and right stiles (type 11)

[0080]5′: the left and right stiles (type 1);

[0081]7: the plastic-extruded interior reinforced material;

[0082]71: door panel (type A);

[0083]8: top stile;

[0084]81: door panel (type B);

[0085]9: bottom stile;

[0086]91: door panel (type C);

[0087]10: handle's reinforced material;

[0088]13: the concave part at the middle area of plastic-extruded interior reinforced material;

[0089]14: the left and right stiles having a groove shape;

[0090]15: polyurethane foam;

[0091]16: the concave part at two sides' top and bottom areas of plastic-extruded interior reinforced material;

[0092]17: the convex parts at two sides of door panel;

[0093]18: the convex hollow construction of plastic-extruded interior reinforced material. 

What I claimed is:
 1. A press-molded door with an improvement for its interior reinforced material and stile structure comprising two door panels, two top and bottom stiles, two left and right stiles and an interior reinforced material, wherein the improvement comprise that the convex construction of flexible-rigid co-extrusion of door's left and right stiles can be inserted with the concave construction of door's interior reinforced material, and interior reinforced material of single molding can reduce assembly time and increase the door strength and quality stability, and after that, setting the handle's reinforced materials inside the interior reinforced material to form a closed space with two top and bottom stiles, and therefore, constitute an imitation wood grain door.
 2. A press-molded door of claim 1 , wherein said left and right reinforced material are groove-shaped, to be inserted with the convex part of the left and right stiles; and after that, it is matched with said top and bottom stiles and two door panels to form a closed space; finally to get an imitation wood-grain door by drilling a hole at the bottom stile to be good for filling polyurethane into its inner space.
 3. A press-molded door of claim 1 , wherein the width of the door width can be changed by cutting the width of two sides of said assembly door to meet the requirements of the customer.
 4. A press-molded door of claim 1 , wherein the width of the door can be changed as required by setting different width of left and right stiles. 